STUD.25K05 - Stud-Xtractor Broken Bolt Removal Electrode 2.5mm 0.5kg

Technical Overview: Stud-Xtractor SMAW Electrode

The Stud-Xtractor 2.5mm (3/32") is a highly specialized Shielded Metal Arc Welding (SMAW) electrode formulated specifically for the extraction of broken steel studs and bolts from carbon steel or cast iron components. Unlike standard joining electrodes (like E7018 or E6013), the Stud-Xtractor features a proprietary coating that creates a non-conductive shield around the arc. This characteristic is critical when working inside a threaded hole, as it prevents the filler metal from arcing against or fusing to the internal threads of the workpiece.

The core wire is engineered to provide extremely high tensile strength. This ensures that the "nub" or extension built up on the broken stud can withstand the high torque required to back the fastener out once it has cooled. The 2.5mm diameter allows for precise arc control on studs ranging from M6 to M12 (1/4" to 1/2"), providing enough clearance for the flux to perform its insulating duty. The electrode operates with a stable arc on both AC and DC currents (DCEP recommended for best penetration into the stud face), making it compatible with virtually any stick welder found in a maintenance shop.

Application Procedure:

1. Clean the area to remove oil or grease.
2. Select an amperage setting appropriate for 3/32" (approx. 60-90A).
3. Strike the arc directly on the center of the broken stud.
4. Maintain a short arc and build up a pool of metal. Stop and remove slag between passes if building a significant height.
5. Continue building until the weld metal protrudes above the surface.
6. Weld a nut or washer to the top of the buildup for gripping.
7. Allow the assembly to cool slightly; the contraction will aid in loosening the rust bond.
8. Apply steady torque to extract the stud.

This 0.5 kg packaging is designed for MRO (Maintenance, Repair, and Operations) environments where these electrodes are used intermittently but are critical when needed. The formulation ensures long shelf life when stored correctly.